TPU 60A Soft Robotics: Stronger, Flexible 3D Printing with Filaflex
3D-Printed TPU 60A: The Future of Soft Robotics Without Silicone or Molds
Forget messy silicone casting and rigid TPU. This groundbreaking study from Kyoto University of Advanced Science proves that highly flexible TPU 60A and 70A can be 3D printed with outstanding results—producing grippers that are stronger, more flexible, and faster to fabricate than traditional soft robotic designs.
The Problem: Silicone Molding and Rigid TPU Are Holding Us Back
For years, soft robotic grippers have relied on silicone molding—an outdated, time-consuming, and fragile method that involves complex mold-making and long curing times. While FDM 3D printing has emerged as an alternative, most implementations have used TPU 85A, which is often too stiff for high-performance soft robots.
The Breakthrough: TPU 60A and 70A as Viable FDM Materials
This study shows that soft TPU materials like Filaflex 60A and 70A can be successfully 3D printed on a standard Prusa MK4 printer to create complex geometries such as pneumatic bellows. The results far surpass silicone-based methods in both flexibility and durability.
Each gripper took around 10 hours to print—no molds or curing needed.
Powerful Performance: Force, Flexibility, Versatility
- Raw Force: The 60A TPU gripper lifted 1297 g (a full spool of filament) vs. only 230 g for a silicone-based version.
- Flexibility: At 200 kPa, the TPU 60A gripper bent to 104°, the 70A to 81°, while 85A barely reached 42°.
- Versatile Grip: Thanks to its pneumatic triangular design, the same gripper handled delicate items (like a 55 g egg) and heavy tools.
The Technical Recipe: Yeoh 3rd-Order Hyperelastic Model
To give engineers a simulation-ready toolkit, the team validated the Yeoh 3rd-order hyperelastic model as the most accurate way to simulate TPU 60A/70A in FEA software. With just 6° of error margin, this model enables reliable digital prototyping—saving time and materials.
Conclusion: A New Era for Soft Robotics, Powered by Filaflex
This research proves that materials like Filaflex 60A and 70A are not just printable—they outperform traditional silicone in almost every way. Stronger grip, higher bending angles, and faster, mold-free production make them ideal for the next generation of soft robotic systems.
The future of flexible, functional robotics is not molded—it's 3D printed.
Source
“Materials and Methods for Designing 3D-Printed Soft Robot Grippers in Low-Hardness TPU (60A–70A)”
Khalid Meitani, Sajid Nisar. IEEE Access, Vol. 13, 2025.
DOI: 10.1109/ACCESS.2025.3642169